Modular turnout gear with full body barrier garment

ABSTRACT

A modular turnout personal protective garment is described that includes a full body barrier garment fabricated from a moisture barrier layer. The full body barrier garment may optionally be worn alone or under one or more of a separate jacket and trouser portion. The jacket and trouser portion are fabricated from an abrasion resistant layer and a thermal insulation layer and are configured to be worn over the moisture barrier full body barrier garment layer.

RELATED APPLICATIONS

This application claims benefit of U.S. Provisional Application Ser. No. 62/817,741 that was filed on Mar. 13, 2019. The contents of Application 62/817,741 are hereby incorporated by reference herein.

TECHNICAL FIELD

The present disclosure relates generally to personal protective equipment. Specifically, the present disclosure relates to modular turnout gear for emergency responders.

BACKGROUND

Firefighters and other emergency responders may engage in a wide variety of activities associated with different levels of risk. Frequently, responders are exposed to a variety of hazardous conditions such as flame, smoke, toxic chemicals and high heat. Clothing used by such professionals may be designed to protect against one or more of these specific conditions in addition to being abrasion resistant, flame resistant, chemical resistant, and waterproof.

In efforts to minimize risk, organizations such as the National Fire Protection Association (NFPA) provide standards for the clothing that firefighters and other responders wear while performing various activities. By way of example, NFPA standard 1971 identifies design and performance criteria for garments that are to be used in structural firefighting, including proximity firefighting. The European Union has also established standard EN 469 that defines criteria for clothing worn by firefighters and other responders.

SUMMARY

Example 1 is a modular personal protective ensemble comprising: a full body barrier garment comprising a torso portion integral with a leg portion, the full body barrier garment comprising a moisture barrier layer; a jacket configured to be worn over the torso portion of the full body barrier garment and a first abrasion resistant layer; and a trouser portion configured to be worn over the leg portion of the full body barrier garment, the trouser portion comprising a second abrasion resistant layer.

Example 2 includes the subject matter of Example 1 and the moisture barrier layer and flame resistant layer comprise a laminate.

Example 3 includes the subject matter of Example 1 or 2, further comprising a thermal insulation layer on an interior of the full body barrier garment.

Example 4 includes the subject matter of any of Examples 1-3, comprising a thermal insulation layer on an interior surface of one or both of the jacket and the trouser portion.

Example 5 includes the subject matter of any of Examples 1-4 and the full body barrier garment comprises a moisture barrier layer laminated to a knit material.

Example 6 includes the subject matter of any of Examples 1-5 wherein the flame resistant layer is an abrasion resistant layer.

Example 7 includes the subject matter of any of Examples 1-6, wherein the insulation layer comprises one or more of a woven fabric, a non-woven fabric, a knit fabric, a laminate, and a stretch material.

Example 8 includes the subject matter of any of Examples 1-7, wherein the ensemble has a minimum total heat loss of 205 Watts/meter² in accordance with NFPA 1971.

Example 9 includes the subject matter of any of Examples 1-8 and the ensemble complies with NFPA 1971 for particle blocking.

Example 10 includes the subject matter of any of Examples 1-9, wherein a thermal insulation layer of the jacket and the trouser portion confronts the moisture barrier layer of the full body barrier garment when the jacket and the trouser portion are worn over the full body barrier garment.

Example 11 includes the subject matter of any of Examples 1-10, wherein the full body barrier garment further comprises an optically reflective material.

Example 12 includes the subject matter of any of Examples 1-11, wherein the full body barrier garment and one or more of the jacket and the trouser portion define a gap that at least partially separates the full body barrier garment from one or more of the jacket and the trouser portion when the one or more of the jacket and the trouser portion are disposed over the full body barrier garment.

Example 13 includes the subject matter of any of Examples 1-12, wherein the full body barrier garment further comprises at least one first fastener disposed on an outer surface of the full body barrier garment, and one or more of the jacket or the trouser portion comprises at least one second fastener disposed on a corresponding inner surface of one or more of the jacket or the trouser portion, wherein the at least one second fastener is configured to releasably connect to the at least one first fastener. The first and second fastener can be a zipper.

Example 14 includes the subject matter of any of Examples 1-13, wherein the moisture barrier layer comprises one or more of polyurethane, polytetrafluoroethylene (PTFE), expanded PTFE, aramids, para-aramids, meta-aramids, polyester, polyether, polyacrylate, copolyether ester, and copolyether amide.

Example 15 includes the subject matter of any of any Examples 1-14, wherein any abrasion resistant layers comprise fibers of one or more of a meta-aramid, a para-aramid, polybenzimidaxazole (PBI), polybenzobisoxazole (PBO), fire resistant rayon, modacrylic, and melamine.

Example 16 includes the subject matter of any of any Examples 1-15, wherein the full body barrier garment further comprises one or more of: a collar; a collar cuff; a hood attached to one of the collar, the collar cuff, or the torso portion of the full body barrier garment; a first bootie attached to a first leg of the leg portion of the full body barrier garment; a second bootie attached to a second leg of leg portion of the full body barrier garment; a first sleeve; second sleeve; a first sleeve cuff attached to the first sleeve; a second sleeve cuff attached to the second sleeve; a first glove attached to one of the first sleeve or the first sleeve cuff; and a second glove attached to one of the second sleeve or the second sleeve cuff.

Example 17 includes the subject matter of Example 16, wherein one or more of the first glove, the second glove, the first bootie, the second bootie, and the hood are releasably attached to a corresponding portion of the full body barrier.

Example 18 includes the subject matter of any of any Examples 1-17, wherein the trouser portion comprises one or more of a first trouser leg; a first trouser leg cuff attached to the first trouser leg; a first bootie attached to one or more of the first trouser leg and the first trouser leg cuff; a second trouser leg; a second trouser leg cuff attached to the second trouser leg; and a second bootie attached to one or more of the second trouser leg and the second trouser leg cuff.

Example 19 includes the subject matter of Example 18, wherein the first bootie and the second bootie are releasably attached to a corresponding trouser leg.

Example 20 includes the subject matter of any of Examples 1-19, wherein the jacket comprises one or more of a collar; a collar cuff; a hood; a first sleeve; second sleeve; a first glove attached to the first sleeve; a second glove attached to the second sleeve; a first sleeve cuff; and a second sleeve cuff.

Example 21 includes the subject matter of Example 20, wherein one or more of the hood, the first glove and the second glove are releasably attached to a corresponding portion of the jacket.

Example 22 includes the subject matter of any of the preceding Examples, and the moisture barrier complies with standard EN 469.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates traditional turnout gear that includes a jacket and pants.

FIG. 1B illustrates the arrangement of the traditional jacket and pants depicted in FIG. 1A when worn together.

FIG. 2 is a cross sectional view of the sequence of layers used for the fabric in jacket and pants of the traditional turnout gear depicted in FIGS. 1A, 1B.

FIG. 3A illustrates a modular jacket and trousers worn over a full body barrier garment, in an example of the present disclosure.

FIGS. 3B and 3C are cross-sectional views of layers of fabric when a modular jacket and trousers are worn over a full body barrier garment, in examples of the present disclosure.

FIG. 4A is a schematic depiction of a full body barrier garment of modular personal protective clothing, in an example of the present disclosure.

FIG. 4B is a cross-sectional view of an example fabric used for a full body barrier garment, in an example of the present disclosure.

FIG. 4C is a cross-sectional view of an alternative example fabric used for a full body barrier garment, in an example of the present disclosure.

FIG. 4D is a cross-sectional view of an alternative example fabric used for a full body barrier garment, in an example of the present disclosure.

FIG. 4E is a schematic depiction of a full body barrier garment of modular personal protective clothing that includes booties, gloves, and a hood, in an example of the present disclosure.

FIG. 5A illustrates modular jacket and trousers of personal protective clothing worn over the moisture barrier full body barrier garment depicted in FIG. 4A, in an example of the present disclosure.

FIG. 5B is a cross-sectional view of an example fabric configuration that can be used for modular jacket and pants depicted in FIG. 5A, in an example of the present disclosure.

The figures depict various embodiments of the present disclosure for purposes of illustration only. Numerous variations, configurations, and other embodiments will be apparent from the following detailed discussion. Furthermore, as will be appreciated, the figures are not necessarily drawn to scale or intended to limit the described embodiments to the specific configurations shown. For instance, while some figures generally indicate straight lines, right angles, and smooth surfaces, an actual implementation of the disclosed techniques may have less than perfect straight lines and right angles, and some features may have surface topography or otherwise be non-smooth, given real-world limitations of fabrication processes. In short, the figures are provided merely to show example structures.

DETAILED DESCRIPTION Overview

Garments that are used in firefighting can be uncomfortable to wear. Firefighting garments (referred to as “turnout gear”) can be bulky and cumbersome, inhibiting the free and easy movement of the wearer. Turnout gear often includes trousers (often in the form of overalls, which may partially cover a mid-section and/or torso of a wearer), and a jacket that at least partially overlaps the pants. Turnout gear often retains a large amount of body heat, rendering the gear uncomfortably warm under many circumstances.

FIGS. 1A and 1B illustrate a typical configuration of turnout gear used by an emergency responder. FIG. 1A illustrates the two traditional components: jacket 104 and pants 108. When worn together, the jacket 104 and the pants 108 collectively assemble to form the suit 100, an assembled view of which is depicted in FIG. 1B. Concurrent reference to FIG. 1A and FIG. 1B may facilitate explanation.

The jacket 104 includes sleeves 106, a central portion 110, a collar 112, a fastener 116, and a fastener cover 118. In this example, the central portion 110 is dimensioned and configured to enclose the shoulders, the chest, and the waist of a wearer (including underlying clothing and/or protective equipment). In some examples, the sleeves 106, the collar 112, the fastener 116, and the fastener cover 118 are all connected to, and integral with, the central portion 110. The sleeves 106 and the collar 112 are designed and configured to cover and consequently protect some or all of the arms and neck of the wearer.

To improve the protection, the sleeves 106 may also include sleeve cuffs 120. These cuffs 120 can be fabricated from a material that can constrict around the wrists and neck of the wearer so as to prevent foreign gases and particles from entering the sleeves 106 and collar 112.

Similarly, the fastener 116 and the fastener cover 118 also prevent foreign materials from becoming disposed between an interior surface of the jacket 104 and the wearer. The fastener 116 releasably connects confronting and separable portions of the central portion 110 to one another. The fastener 116 can include one or more of a zipper, compression snaps, and/or hook and loop fasteners. The fastener cover 118 is a strip of material that covers the fastener 116, thus reducing infiltration of foreign material through the fastener 116 (or portions of the jacket 104 not sealed by the fastener 116). In some examples, the fastener cover 118 is sewn, joined, or otherwise is integral with the jacket 104 on a first side of the fastener 116. Confronting surfaces of the jacket 104 and the fastener cover 118 can have snaps and or complementarity hook and loop fasteners. Regardless, these types of conveniently reversible fasteners can releasably affix the fastener cover 118 to an exterior surface of the jacket 104. This enables the fastener 116 to be covered and uncovered, as desired by the wearer, so as to temporarily cover the fastener 116.

The jacket 104 may optionally include optically reflective strips 128 on an exterior surface. The optically reflective strips 128 reflect incident light, thus enabling the wearer of jacket 104 to be seen in low light conditions. Examples of low light conditions include but are not limited to dusk, dawn, night, conditions in which ambient light is reduced intensity by for example smoke, and interiors of buildings or enclosed spaces without artificial or natural lighting.

Pants 108 of the suit 100 in this example include suspenders 132, pant legs 136, articulated knees 140, cuffs 144, and reflective strips 148. The pants 108 can be made from the same fabric (including the same layers of materials) as the jacket 104. This fabric and its corresponding layers are described below in the context of FIG. 2

The suspenders 132 are dimensioned and configured to be worn over the shoulders of a wearer so as to maintain the proper position of the pants 108 during use. The suspenders 132 can be fabricated from a same material as that of the jacket 104 and/or pants 108, or can be fabricated from a (flame resistant) material more easily adjustable and more comfortably worn, such as cotton, nylon, polyester, or blends thereof. The material for the suspenders 132 may also include an elastic component that may assist in maintaining the proper position of the pants 108 during use and also improve the convenience with which the suspenders 132 can be fit to the wearer. Pant legs 136 are configured to cover any portions of the wearer not covered by the jacket 104, thus protecting the lower portion of the body of the wearer. Articulated knees 140 allow a greater range of motion as the wearer walks, runs, jumps, crawls, crouches or otherwise bends and extends knees. It will be appreciated that the techniques used to form articulated knees 140 can be optionally applied to other portions of the suit 100, such as those corresponding to the elbows and shoulders of a wearer. Cuffs 144 and reflective strips 148 are analogous to those described above in the context of the jacket 104 and need not be described further.

FIG. 1B illustrates an assembled state of the suit 100. The various elements of the jacket 104 and pants 108 have been described above and need no further explanation. As can be seen from this figure, the jacket 104 and pants 108 overlap one another in overlap region 152. This overlap region 152 can have several uses. In one example, it allows exposure of a reflective strip 128 (not shown in FIG. 1B but visible in FIG. 1A) at a waist location of the jacket 104. This can improve visibility of a wearer under low light conditions. The overlap region 152 also can prevent foreign material from becoming disposed between the pants 108 and the wearer by covering the waist portion of the pants 108. A cuff 124 may also be associated with the collar 112.

FIG. 2 illustrates the layers of materials that form the fabric 200 used in the jacket 104 and the pants 108, in one example. The layers in the fabric 200 can include an abrasion resistant layer (or “outer shell”) 204, a moisture barrier layer 208, and a thermal insulation layer 212.

The abrasion resistant layer 204 is a durable layer that provides abrasion and/or wear resistance, as well as some thermal protection and fire resistance, among other aspects. The outer shell 204 typically covers a majority of the exterior surface of the jacket 104 and the pants 108. In some examples, the abrasion resistant layer 204 is made from synthetic fibers that include aramids, meta-aramids, and para-aramids such as KEVLAR® among others.

Modular Turnout Gear with Full Body Barrier Garment

Protective garments described above in the context of FIGS. 1A, 1B, and 2 and complying with NFPA 1971 often retain body heat of the wearer, as is reflected in the requirement of a minimum of 205 Watts per square meter (W/m²) Total Heat Loss criteria. Regardless of the NFPA heat loss requirement, body heat retention can present a number of problems. For example, if an emergency responder is traveling to an event wearing turnout gear 100, the responder may be uncomfortably hot even before arriving at the scene of the event. In another example, not every event that an emergency responder attends requires all of the layers of the fabric 200. For some cases, such as a technical rescue, the fabric 200 may actually impede efforts to respond to the event by providing “protection” against threats not present at the event. That is, the weight, bulk, and added thermal insulation may cause emergency responders to move slower, tire faster, and become dehydrated faster, thus impairing the speed, effectiveness, and accuracy of their response. For these reasons, responders may prefer not to wear 1971 compliant structural firefighting protective clothing when performing other types of emergency response activities, such as technical rescue operations or when responding to events that do not involve fire.

The disadvantages of turnout gear incorporating fabric 200 (or otherwise complying with NFPA 1971) are outweighed when the level of protection provided is necessary, for example in the event of a structural fire. However, the integration of the layers of fabric 200 with one another in both the jacket 104 and the pants 108 precludes selection of only those layers 204, 208, 212 that are necessary for responding to an event that may require a lower level of protection than that provided by the collection of all of the layers 204, 208, 212.

In accordance with some embodiments of the present disclosure, FIGS. 3A, 3B, and 3C depict (at a high level) a modular turnout gear suit 300 that includes a full body barrier garment 304 fabricated from a moisture barrier layer that is worn as a separate garment, optionally within a jacket 308 and a trouser portion (or “trousers”) 312. The moisture barrier layer can form part of the garment that is worn against the skin of the wearer. Various configurations of the modular turnout gear suit (or equivalently “ensemble”) and full body barrier garment 304 are possible. For example, FIGS. 3B and 3C illustrate different configurations of layers between jacket 308, trouser portion (or “trousers”) 312, and full body barrier garment 304.

The ensembles described herein provide a number of advantages over currently available turnout gear. For example, the full body barrier garment can be used by itself to respond to events that do not require full turn out gear that includes thermal insulation. The full body barrier garment can, by itself, protect against hazards such as fluids, vapors, smoke, particles, nanoparticles, bacteria and viruses. Wearing the full body barrier garment by itself is significantly more comfortable than wearing full structural fire turnout gear. It also allows the wearer to maneuver more easily, such as might be required during a technical rescue. When the responder needs to respond to a structural fire, the jacket and trousers of the ensemble can be quickly donned over the full body barrier garment to provide full NFPA 1971 structural fire protection. The jacket and trousers need not include a moisture barrier, as an adequate moisture barrier can already be contained in the full body barrier garment. In practice, the full body barrier garment can be worn in the response vehicle on its way to an event and the jacket and trousers can be donned upon, or shortly before, arrival. This helps keep the wearer cool for as long as possible.

The ensemble can include one or more abrasion resistant layers. An abrasion resistant layer is a durable layer that provides abrasion and/or wear resistance, as well as some thermal protection and fire resistance, among other aspects. An abrasion resistant layer is typically a synthetic such as aramids, meta-aramids, and para-aramids such as KEVLAR. Abrasion resistant layers are more resistant to abrasion than are natural fiber layers such as cotton or wool and are more resistant than standard polymeric fabrics such as polyester. The outer shell of the ensemble is abrasion resistant because it is the outer shell than is subject to the most abrasion wear. The outer layer of the full body barrier garment may also be an abrasion resistant material.

The full body barrier garment, the jacket and/or the trousers can include a moisture barrier layer to prevent or inhibit the ingress of solids, nanoparticles, microparticles, macro particles, suspensions thereof, liquids, and/or vapors in accordance with NFPA 1971 and/or EN 469.

One or more of the garments of the ensemble can include a thermal insulation layer. A thermal insulation layer is a layer that meets the definition of NFPA 1971 section 3.3.141. The thermal insulation layer is in large part (although not exclusively) responsible for personal protective equipment complying with the heat protection standards described in NFPA 1971. Performance related aspects of structural firefighting garment standards (i.e., structural firefighting aspects of NFPA 1971) indicate a minimum Thermal Protective Performance (TPP) score of 35. A thermal insulation layer can be, in some embodiments, a knit, a mesh or a quilted layer. This layer can be disposed on an innermost layer or a mid layer of any of the jacket, the trousers and/or the full body barrier garment. It can also be disposed on the outside of the full body barrier garment or the jacket and/or trousers and can also function as an abrasion resistant layer.

As used herein, a full body barrier garment is a single piece garment that includes openings for both arms and legs (or includes integral booties) and typically includes both sleeves and trouser legs. In some embodiments, the full body barrier garment may include booties and/or gloves to protect feet and hands of a wearer. The booties may be integral or separate. The garment can also include a hood that can be attachable or integral. In any of the various embodiments described herein and/or apparent in light of the following description, the full body barrier garment can be donned by stepping into the full body barrier garment through an opening and zipping or otherwise closing the opening after placing the legs and arms through the appropriate openings. In many embodiments, a single zipper or other closure is adequate to seal the entire garment.

In some embodiments, the full body barrier garment can be fabricated from one or more fabric types and fabric compositions. For example, some of the example full body barrier garments described herein can be fabricated from one or more of woven, fleece, knit and non-woven materials (e.g., membranes, coatings). These can be assembled as fabrics, laminates, and combinations thereof. While example materials are listed below for the various layers, it will be further appreciated that panels or regions of the full body barrier garment, in particular those where a wide range of movement is desired (e.g., under arm, shoulder, back, knee), may include stretchable fibers, fabrics, fabric panels, laminates, and combinations thereof. In some cases, stretchable barrier layers used for example in full body barrier garments can improve the comfort of the full body barrier garment during use while at the same time reducing the exposure to contaminant particles (e.g., nanoparticles). In some cases, the stretchability is characterized as “2-way” or “4-way,” referring the number of directions in which the panel can elastically deform in response to an applied stress. A material is considered to be stretchable when it can be elastically elongated by pulling in opposite directions by hand. In various embodiments, the material may stretch at least 2% of length and in others, at least 5% or at least 10% of length. A stretchable material returns to its original orientation when the tension is relieved. The stretching function can be integrated into the product by using a material made from elastic yarn or thread and/or can be provided by using a material that incorporates a weave pattern that allows the fabric to stretch without actually elongating the yarn or thread. In some cases, both techniques can be employed.

While a more detailed description of each of the full body barrier garment 304, jacket 308, and the trouser portion 312 follows in the context of FIGS. 4A, 4B, 4C, 4D, 4E, 5A, and 5B, some advantageous features of the modular turnout gear suit 300 can be seen with reference to FIGS. 3A, 3B, and 3C.

For example, as is apparent upon inspection of FIG. 3A, the full body barrier garment 304 can be worn as a single garment over the torso, arms and legs of a wearer and optionally underneath one or both (or neither) of the jacket 308 and/or the trousers 312. In this example, the full body barrier garment 304 includes first fasteners 316. The first fasteners 316 are configured to connect to corresponding second fasteners (not shown) on one or both of an interior, confronting surface of the jacket 308 or the trousers 312. In the particular example shown, the upper limit of the trousers 312 is waist band 322, which is below the first fasteners 316. In examples in which the second fasteners are associated with the trousers 312, the waist band 322 will overlap the first fasteners 316 so that the first fasteners 316 can connect to the second fasteners, thus replacing the suspenders illustrated in FIG. 1A. A collar 332 may also be configured to surround the neck of a wearer. The collar can include a moisture barrier above the collar seam. For example, the moisture barrier (or a filter layer) may extend upward from the collar seam by greater than 0.5 inch, greater than 1.0 inch or greater than 1.5 inch.

In another aspect, the suit 300, the full body barrier garment 304, the jacket 308, and the trousers 312 include portions to improve visibility in smoky or low light conditions. These portions can include reflective strips or one or more sections of optically bright colors, such as luminous (safety) orange, yellow or green. The color and/or optically reflective strips 320 on the full body barrier garment 304 can increase the visibility of the full body barrier garment 304 in low light conditions when the full body barrier garment 304 forms the outermost layer of the suit 300 (i.e., because one or both of the jacket 308 and trousers 312 is not worn). Optically reflective strips 324 are disposed on exterior surfaces of the jacket 308 and trousers 312 so that the wearer of the suit 300 remains visible even when the optically bright areas on the full body barrier garment 304 are covered.

Another aspect of the suit 300 is that cuffs can be integral to the full body barrier garment 304. As can be seen from FIG. 3A, cuffs 328 are attached to the sleeves 336 and trouser legs 340 of the full body barrier garment 304 and need not be attached to corresponding portions of the jacket 308 or the trousers 312. This enables the wearer of the full body barrier garment 304 to be protected against exposure to foreign material even when wearing only the full body barrier garment 304 and not the jacket 308 or the trousers 312. Note that other configurations of terminal structures for sleeves (e.g., gloves), trousers (e.g., booties), and collar (e.g., a hood) are described below in the context of FIG. 4E. These terminal structures can be fixedly attached (e.g., sealed sewn or welded seams) or releasably attached (e.g., hook and loop fastener, zipper). Furthermore, it will be appreciated that as used herein in the context of the suit 300 (and various embodiments thereof), the term “cuff” can include various terminal structures for sleeves, trousers, and collar. In some cases, a cuff can include a sewn end of a sleeve or trouser that is designed to easily fit over a boot or glove. In other examples, a cuff can include a wrister, a water well, a boot seal, an elasticized structure configured to contract around the leg, ankle, arm, wrist, or neck of a user (e.g., a stretch/elasticized knit fabric, woven fabric, laminate, membrane), thereby reducing the exposure of the wearer to contaminants. In some examples a cuff includes structures to establish a water tight or particle tight seal between a sleeve or trouser and a corresponding glove or boot.

The seal at the openings (cuffs, ankle, neck) of the full body barrier garment can help to prevent the intrusion of liquids, gases and particles. The seal can include a barrier that can be either a membrane barrier or a filtration layer. A membrane barrier protects the wearer from particle (including nanoparticles) intrusion by physically blocking the passage of gases, liquids and solids. An example of a membrane barrier is one incorporating PTFE, such as CROSSTECH®, CROSSTECH BLACK® or CROSSTECH 3-Layer® moisture barrier. A filtration layer protects the wearer by allowing the inflow and outflow of some gases but protecting against particle intrusion by catching the particles as would a filter. Examples of a filtration layer are electrospun aramids such as NOMEX NANOFLEX®. These seals can result in a garment, such as full body barrier garment 304, that meets the optional Particle Blocking Ensemble section of NFPA 1971.

Turning now to FIG. 3B, still another aspect of the suit 300 can be seen in the arrangement of the layers relative to one another. When the full body barrier garment 304, the jacket 308 and/or the trousers 312 are worn together, an abrasion resistant layer 348 is disposed at an exterior surface of the suit 300 (i.e., exposed to the environment and not the wearer). The moisture barrier layer 360 is on an inner surface, disposed adjacent to the wearer of the suit 300. This is different from the example depicted in FIG. 2 in which the moisture barrier layer 208 is disposed between the abrasion resistant layer 204 in the thermal insulation layer 212. Furthermore, because the full body barrier garment 304 is a separate garment and distinct from the jacket 308 and the trousers 312, the moisture barrier layer 360 of the full body barrier garment 304 and the confronting interior surface of the thermal insulation layer 352 define a gap 356. This gap 356 clearly indicates that the separate garments and layers are not integral with one another but rather are constituents of distinct and separable garments. It will be appreciated that the gap 356 is indicated as a discontinuity between the different garments and will change shape and/or dimensions as the wearer moves. The gap 356 can be continuous but need not be. In some examples it can be discontinuous or otherwise only partially separate different garments or portions of garments. Note that the full body barrier garment and the trousers or jacket can be joined by connectors such as zippers, snaps or hook and loop, but that the gap between the garments substantially remains.

FIG. 3C illustrates another arrangement of layers relative to one another. As shown, in some embodiments the full body barrier garment 304 may include an optional thermal insulation layer 352 in addition to the moisture barrier, with gap 356 separating the full body barrier garment 304 from the abrasion resistant layer of the jacket 308 and/or trousers 312.

Alternative configurations of material layers for the full body barrier garment 304 are described below in the context of FIGS. 4C and 4D.

Moisture Barrier Full Body Barrier Garment

FIGS. 4A, 4B depict the moisture barrier full body barrier garment 304 that can be worn separately from other personal protective garments that may be found in other configurations of turnout gear, such as those illustrated in FIGS. 1A, 1B, and 2. FIGS. 4A, 4B depict the full body barrier garment 304 in the absence of the jacket 308 and the trousers 312. However, concurrent reference between FIGS. 3A, 3B, 4A, and 4B may facilitate explanation.

As indicated above, configuring personal protective clothing so that an emergency responder can wear the moisture barrier full body barrier garment 304 alone or in combination with one or both of jacket and pants (that include the abrasion resistant layer and the thermal insulation layer) provides flexibility to tailor personal protective equipment to the conditions of the event being responded to. This flexibility reduces the likelihood that an emergency responder will be uncomfortable, tired, dehydrated, or otherwise physically hampered by the personal protective equipment.

Turning first to FIG. 4A, the full body barrier garment 304 includes a torso portion 404 (which further includes a central portion 406 and sleeves 410), a leg portion 408, a collar 412, cuffs 328, torso portion fastener 416, fastener cover 420, and first fasteners 316.

The full body barrier garment 304 is configured to prevent exposure of the wearer of the full body barrier garment 304 to foreign materials. As indicated above, these can include nanoparticles, microparticles, macro particles, (hot) gases, (hot) liquids, water, and fire extinguishing chemicals and foams. In addition to these foreign materials, because the full body barrier garment 304 is configured to be worn in some circumstances without one or more of a jacket and trousers, the full body barrier garment 304 may also prevent exposure to foreign materials associated with other types of events that are not related to a structural fire, such as a vehicle accident or personal injury (e.g., an event where a risk is exposure to blood).

As shown in FIG. 4B, the full body barrier garment 304 can be fabricated from materials used for a moisture barrier layer 360 and that comply with relevant portions of NFPA 1971. As used herein, a moisture barrier meets the moisture barrier definition of NFPA 1971 (2018 ed) section 3.3.82. The moisture barrier 360 can be fabricated from woven fabrics, knit fabrics, laminates, stretch fabrics, non-woven fabrics, membranes, coatings, and combinations thereof. The moisture barrier 360 may include one or more layers. For example, the moisture barrier 360 may be a laminate comprising a backing material or support layer (sometimes referred to a substrate) laminated to a layer of semi-permeable membrane material.

According to some embodiments, the moisture barrier 360 may include selectively permeable materials such as semi-permeable or “breathable” membranes that resist the transfer of liquid water but are water vapor permeable and may be flame resistant. Selectively permeable materials can include, for example, polyurethane, polytetrafluoroethylene (PTFE), polyester, polyether, polyacrylate, copolyether ester and copolyether amides. Some preferred breathable membranes include expanded PTFE and expanded PTFE (ePTFE) such as described in U.S. Pat. No. 4,187,390 which is hereby incorporated by reference herein. Other non-limiting examples of materials that may be used in one or more layers of a moisture barrier 360 include aramids such as NOMEX, para-aramids such as poly para-phenyleneterephthalamide, and meta-aramids. Some additional trade names of moisture barriers that may be used include STEDAIR GOLD® and CROSSTECH BLACK®. For some embodiments, breathability of the moisture barrier 360 can be within any of the following ranges: 500 g/m²-24 hours to 1000 g/m²-24 hours; 750 g/m²-24 hours to 2000 g/m²-24 hours; 1500 g/m²-24 hours to 3000 g/m²-24 hours; 2500 g/m²-24 hours to 10,000 g/m²-24 hours; greater than 500 g/m2. Other example configurations of layers of the full body barrier garment 304 are described below in the context of FIGS. 4C and 4D.

As indicated above, one function of the full body barrier garment 304 is to act as a moisture barrier when worn with or without one or more optional overlying garments (e.g., jacket and pant, described below in the context of FIGS. 4A, 4B). However, because the full body barrier garment 304 can be worn on its own (or with only one of the jacket or pant) in some embodiments, the full body barrier garment 304 includes features not normally associated with the moisture barrier in traditional protective wear (e.g., the example suit 100). For example, an outer surface of the full body barrier garment 304 includes optically bright areas such as reflective strips 320 on both the torso portion 404, and more specifically on central portion 406 and sleeves 410. The full body barrier garment 304 also includes optically bright areas on the leg portion 408. As indicated above, the optically bright areas increase visibility of the user in low light conditions when wearing the full body barrier garment 304 as an exterior garment. The optically bright areas can be reflective strips 320 that can be fabricated from reflective tape or reflective material, and adhered to or sewn to (or within) the full body barrier garment 304. An example of reflective material is SCOTCHLITE® reflective strips. More generally, optically reflective strips 320 can be designed so as to meet the requirements of reflective trim in NFPA 1971.

In another example, the outer surface of the full body barrier garment 304 includes first fasteners 316, as shown in FIG. 3A. As described above, the first fasteners 316 are placed at a location on the full body barrier garment 304 so that they can be optionally connected to corresponding second fasteners (shown in FIG. 5A) to one or more of a jacket or a trouser portion.

Cuffs 328 are associated with openings in sleeves 410, and leg portion 408. The cuffs 328, which can be fabricated to constrict around arms and legs of the wearer, are constructed to prevent infiltration of foreign material through these openings. For example, when formed from a heat and flame resistant material that has either an elastic component or is woven so as to have a natural compressive effect, the cuffs 328 can prevent nanoparticles, microparticles, macroscopic particles, smoke particles, melting plastic, embers, bacteria, viruses, body fluids and water (in some non-limiting examples) from becoming disposed between the full body barrier garment 304 and the wearer (not shown) through the open ends of the sleeves 410. Cuffs 328 may be stretchable and can be constructed from an elastic non-woven or knit fabric, such as NOMEX® and NOMEX NANO® (stretch filtration material b/w two knits). In alternative embodiments, the cuffs can include membrane material such as CROSSTECH® to prevent the intrusion of particles and liquids.

Fastener 416 and fastener cover 420 can prevent infiltration of foreign material into the full body barrier garment 304. In different embodiments, fastener 416 can be located in the front or the back of the full body barrier garment. The fastener can be, for example, a zipper or hook and loop fastening system. The fastener and associated opening may also be formed off center so that the opening does not align with the opening on a jacket that is worn over the full body barrier garment. This architecture may provide for improved resistance to gases and particulate matter. Articulated joints 424 have also been described above and need no further explanation. It will be appreciated that articulated joints may also be present at elbows and shoulders of the central portion 406 even though these are not shown in FIG. 4A.

In alternative embodiments, the full body barrier garment 304 can be fabricated to include different combinations of layers, in addition to the configuration of FIG. 4B. For example, FIG. 4C illustrates a full body barrier garment that includes the thermal insulation layer 352 on an interior surface so that, when worn, the thermal insulation layer 352 is between the user and the moisture barrier layer 360. Still another example configuration of the full body barrier garment is shown in FIG. 4D. In this example embodiment, the moisture barrier layer 360 is connected to an abrasion resistant layer 348 so that the abrasion resistant layer 348 is exposed as an exterior surface. In some examples, the moisture barrier may include an abrasion resistant material 348 attached to a surface of the moisture barrier 360 (as shown in FIG. 3D) so that the abrasion resistant material 348 is exposed to an exterior. As indicated in FIG. 4C, in some cases the moisture barrier 360 can be joined or attached or laminated to an insulation layer (on an interior surface) that can be a flame resistant woven, non-woven, knit, and/or stretch fabric. As used herein, a flame resistant layer meets the definition of NFPA 1971 (2018 ed) section 3.3.44. Examples of flame resistant material are woven or knit materials such as TECASAFE® and TECASAFE PLUS®. In other examples, a moisture barrier 360 may be configured with an insulation layer on an interior surface and an abrasion resistant layer on an exterior surface. In some examples, the abrasion resistant layer 348 can be made from synthetic fibers that include aramids, meta-aramids, and para-aramids such as KEVLAR, among others. The various layers can be independent of each other or can be laminated together. An example would be a laminate of a moisture barrier and a flame-resistant layer or a moisture barrier and a woven layer.

It will be appreciated that in some examples of thermal insulation layers (e.g., insulation layer 352) and some examples of abrasion resistant layers (e.g., abrasion resistant layer 348) can be fabricated from woven fabrics, knit fabrics, laminates, stretch fabrics, non-woven fabrics, and combinations thereof. In some examples, thermal insulation layer 352 can be fabricated from a Kevlar knit mesh to provide some stretchability (e.g., 2-way or 4-way stretch) within the insulation layer 352 itself. By way of example, thermal insulation layer 352 may be constructed from one or more synthetic fibers such as a NOMEX cloth quilted to two layers of a 70% NOMEX-30% KEVLAR composite. The thermal insulation layer 352 may alternatively comprise a NOMEX cloth quilted to a 100% NOMEX batting. Further examples of materials that can be used, in whole or in part, for the thermal insulation layer 352 include, but are not limited to, GLIDE GOLD® and QUANTUM3D SL2I®.

Different layers of the moisture barrier 360 itself (e.g., a substrate and an ePTFE layer) may be affixed together by, for example, an adhesive or lamination. Some examples of polymers that may be useful as adhesives include polyurethane, natural latex rubber, nitrile rubber, silicone rubber, butyl rubber, fluorinated rubber, elastomeric copolymers, copolyether polyester, polyester, and/or ethylene vinyl acetate. Similarly, these polymers can be used to attach other layers (e.g., thermal insulation layer 352, abrasion resistant layer 348) to the moisture barrier 360. Additional layers can also be sewn to the moisture barrier layer 360 or attached using a releasable connector (e.g., hook and loop fasteners). Typically, the moisture barrier film (PTFE) will be on the outside of the garment and a woven, knit or other non-film layer will be on the inside. In this case, the film layer will not be in contact with the wearer and, instead, a more comfortable woven layer will be in contact with the wearer.

Different patterns of layers for the full body barrier garment can include, for example, from the inside to the outside: woven or knit layer/moisture barrier; thermal barrier/moisture barrier; woven or knit layer/thermal barrier/moisture barrier; moisture barrier/thermal barrier; woven or knit layer/moisture barrier/flame resistant layer; woven or knit layer/flame resistant layer; woven or knit layer/combination moisture barrier and flame resistant layer. In any of these cases the moisture barrier or the thermal barrier can also be an abrasion resistant layer or have an abrasion resistant layer placed or laminated on top of it.

Turning to FIG. 4E, an alternative embodiment of a full body barrier garment 450 is illustrated. Many of the components of the full body barrier garment 450 have been described above and need no further description. In this example, the full body barrier garment includes one or more of booties 454, gloves 458, and hood 462. The booties 454 can be integral with the leg portion 408 of the full body barrier garment 450 (whether sized to fit a specific foot size or range of foot sizes) or can be removable (e.g., releasably attached) via a fastener (so as to be more easily customizable to a foot size of a wearer). The booties 454 can be fabricated from the same moisture barrier material as the full body barrier garment 450 itself. This layer can protect the wearer and not impede the donning and removal of boots. In other cases, the booties 454 can be fabricated from multiple layers (e.g. a flame resistant abrasion resistant layer and/or a thermal protection layer, among others). Note that in the preferred embodiments, the full body barrier garment meets the flame resistant definition of NFPA 1971 (2018 ed) 3.3.44.

In some examples, instead of booties 454, the leg portion 408 can terminate in an attachment that forms a seal to a boot, such as a “water well” or a flange that can form a vapor/liquid tight seal with trousers. Examples of these configurations are described in U.S. Pat. Nos. 7,921,471 and 8,464,367, which are incorporated by reference in their entireties herein.

Similarly, gloves 458 can be fabricated from the same materials described above in the context of booties 454. The gloves 458 can either integral with or removable (e.g., releasably attached) from the torso portion 404 of the full body barrier garment 450 using the same mechanisms described above in the context of booties 454. In an alternative embodiment applicable to either the full body barrier garment 304 or the full body barrier garment 450, sleeves 410 can terminate in “wristers,” and/or water wells such as those described in U.S. Pat. No. 7,921,471.

Hood 462 can either be integral with or detachable from the full body barrier garment 450 (e.g., at or around the collar 412). In various examples, hood 462 can be fabricated from a barrier layer (e.g., as shown in FIG. 4B, 4C, or 4D), from a woven fabric, a knit fabric, non-woven materials (e.g., laminates, membranes, coatings), and combinations thereof. In one example, hood 462 can be fabricated from a stretch material, such as those described above. Example stretch materials, also indicated above and applicable to any of the previously described embodiments, include elasticized NOMEX and NOMEX NANO (stretch filtration material b/w two knits). The face of the hood can be designed to form a seal with a self-contained breathing apparatus.

Modular Jacket and Trousers

FIG. 5A depicts the jacket 308 and the trousers 312 described above in the context of FIG. 3A, 3B. FIG. 5B shows a cross-sectional view of materials used to fabricate the jacket 308 and the trousers 312.

As shown, jacket 308 includes optically reflective strips 324, a jacket fastener 504, and a jacket fastener cover 508. Analogous elements have been described above and need no further description. Similarly, trousers 312 include optically reflective strips 324, articulated joints 512, and second fasteners 516.

FIG. 5B illustrates the layers forming the jacket 308 and the trousers 312. As shown, these are formed from the abrasion resistant layer 348 on an exterior surface and the thermal insulation layer 352 on an interior surface. In some examples, the abrasion resistant layer 348 can be formed from any of the abrasion resistant materials described above, and optionally include insulation layers and/or stretchable yarns, fabrics, and/or stretchable fabric panels. In some examples, the abrasion resistant layer 348 can be fabricated from woven fabrics, knit fabrics, laminates, stretch fabrics, non-woven fabrics, and combinations thereof. Examples of materials from which the abrasion resistant layer 348 (i.e., outer shell that may or may not be a component of the full body barrier garment 304 but is a component of the jacket 308 and trousers 312) may be constructed include, but are not limited to, meta and para-aramids (NOMEX and KEVLAR), polybenzimidaxazole (PBI), polybenzobisoxazole (PBO), melamine (BASOFIL®), and blends thereof. Some examples of material trade names include PBI MAX and MILLENIA XT® In some examples, fire resistant rayon and modacrylic can be used alone in fabrics or blended with other fibers to form the abrasion resistant layer 348 or portions thereof. It will also be appreciated that in alternative configurations of the ensemble, described herein, the thermal insulation layer 352 may be an optional layer in jacked 308 and trousers 312. For example, the thermal insulation layer 352 need not be incorporated into one or more of the jacket 308 or trousers 312 if the thermal insulation layer 352 is incorporated as layer of the full body barrier layer garment, such as is shown in FIG. 4C.

In some examples, the material used for the abrasion resistant layer 348 is selected to be suitable for use in structural firefighting activities, satisfying that section of NFPA 1971. This may include for example a tear resistance of at least 22 pounds force and tensile strengths of 140 pounds of force or higher.

Thermal insulation layers 352 may be constructed in a variety of ways and from a variety of materials as described above, so as to meet the requirements of structural firefighting garment standards (i.e., structural firefighting aspects of NFPA 1971 and/or EN 469) and have a minimum Thermal Protective Performance (TPP) score of 35 and a heat loss of at least 205 Watts/m². As indicated above, thermal insulation layer 352 may be constructed from one or more synthetic fibers such as a NOMEX cloth quilted to two layers of a 70% NOMEX-30% KEVLAR composite. The thermal insulation layer 352 may alternatively comprise a fabric or composite of multiple fabrics including woven, knit, or non-woven materials in stretch or non-stretch configurations. Another example of thermal insulation layer 352 can include a mesh knit fabric constructed from one or more fibers, such as aramids (e.g., KEVLAR). The thermal insulation layer 352 may include a thermally reflective surface. A thermally reflective surface may be any appropriate thermally reflective material, such as a metalized material. For example, the thermally reflective material may be a substrate supporting an aluminized film. The substrate may be a flexible material and in one embodiment the substrate is a combination of polybenzimidazole (PBI) and poly-paraphenylene terephthalamide, for example, (KEVLAR). In a further embodiment, the substrate may be about 33 percent PBI and about 67 percent meta-aramid and weigh up to 2, 3, 4, 5, 6, 7, 8, or more ounces per square yard, including all weights in between the integers listed. A substrate in a thermally reflective material of the invention can be a knit, woven, or non-woven substrate (e.g., a membrane). The thermally reflective material can be applied to the substrate using any suitable means, including, but not limited to: sewing, coating, lamination, impregnation, casting, or depositing on the substrate. The thermally reflective material may weigh, for example, between 0.25 ounces and 2 ounces per square yard, including all weights between 0.25 and 2. In some embodiments, the sleeves may include a thermally reflective layer that may be absent in the torso.

The thermal insulation layer 352 can be integrated with elements of the jacket 308 or trousers 312 using other layers, such as a liner of a garment. In preferred embodiments, the jacket and trousers include a flame resistant layer. In a few exemplary embodiments, the trousers and/or jacket can include the following patterns of layers or portions of the following patterns of layers, from the inside to the outside: thermal barrier/combination abrasion resistant barrier and flame resistant layer; thermal barrier/flame resistant layer; thermal barrier/abrasion resistant layer; thermal barrier/moisture barrier/abrasion resistant layer; moisture barrier/thermal barrier/abrasion resistant layer. In other embodiments, the jacket or trousers can comprise a single layer such as a flame resistant barrier layer; an abrasion resistant layer; a thermal barrier; or a combination flame resistant layer and abrasion resistant layer.

The ensemble described herein includes the full body barrier garment and the jacket and trousers. Each component of the ensemble can include a flame resistant component as defined in NFPA 1971 The full body barrier garment together with either the jacket or trousers, can, in some embodiments, include the following combinations of layers, working from the inside out: breathable woven or knit fabric/moisture barrier/thermal barrier/abrasion resistant layer; thermal barrier/moisture barrier/abrasion resistant layer; breathable fabric layer/moisture barrier/thermal barrier/abrasion resistant layer

Some of the embodiments disclosed herein can also be used in combination with the subject matter disclosed in U.S. Pat. Nos. 7,921,471; 8,464,367 and 9,409,044. The specification, claims and drawings of these patents are hereby incorporated by reference herein.

FURTHER CONSIDERATIONS

The foregoing description of the embodiments of the disclosure has been presented for the purpose of illustration; it is not intended to be exhaustive or to limit the claims to the precise forms disclosed. Persons skilled in the relevant art can appreciate that many modifications and variations are possible in light of the above disclosure.

The language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter. It is therefore intended that the scope of the disclosure be limited not by this detailed description, but rather by any claims that issue on an application based hereon. Accordingly, the disclosure of the embodiments is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims. 

What is claimed is:
 1. A modular personal protective ensemble of three separate garments, the ensemble comprising: a full body barrier garment comprising a torso portion integral with a leg portion, the full body barrier garment comprising a moisture barrier layer and a flame resistant layer; a jacket configured to be worn over the torso portion of the full body barrier garment, the jacket comprising a first abrasion resistant layer; and a trouser portion configured to be worn over the leg portion of the full body barrier garment, the trouser portion comprising a second abrasion resistant layer.
 2. The modular personal protective ensemble of claim 1 wherein the moisture barrier layer and flame resistant layer comprise a laminate.
 3. The modular personal protective ensemble of claim 1 wherein the full body barrier garment is stretchable by at least 5%.
 4. The modular personal protective ensemble of claim 1 wherein the flame resistant layer is an abrasion resistant layer.
 5. The modular personal protective ensemble of claim 1 wherein the full body barrier garment comprises a moisture barrier layer laminated to a knit material.
 6. The modular personal protective ensemble of claim 1 wherein the ensemble complies with NFPA 1971 for flame resistance, tear strength, breathability, shrinkage, thermal, chemical, and viral penetration resistance.
 7. The modular personal protective ensemble of claim 1 wherein the ensemble complies with NFPA 1971 for particle blocking.
 8. The modular personal protective ensemble of claim 1 wherein the jacket and/or trouser portion exhibits 2 or 4 way elastic stretch of at least 5 percent.
 9. The modular personal protective ensemble of claim 1 wherein the full body barrier garment includes at least a portion that comprises an optically reflective material.
 10. The modular personal protective ensemble of claim 1 wherein the moisture barrier layer is comprised of one or more of polyurethane, polytetrafluoroethylene (PTFE), expanded PTFE, aramids, para-aramids, meta-aramids, polyester, polyether, polyacrylate, copolyether ester, and copolyether amide.
 11. The modular personal protective ensemble of claim 10, further comprising a first thermal insulation layer on an interior of the full body barrier garment.
 12. The modular personal protective ensemble of claim 1 comprising a first thermal insulation layer on the jacket and/or trouser portion.
 13. The modular personal protective ensemble of claim 12 wherein the first thermal insulation layer is positioned as the innermost layer of the jacket and/or trouser portion.
 14. The modular personal protective ensemble of claim 12 further comprising a second thermal insulation layer on the full body barrier garment.
 15. The modular personal protective ensemble of claim 14 wherein the first thermal insulation layer and the second thermal insulation layer, independently fail to meet the thermal requirements of NFPA 1971 and wherein the first thermal insulation layer and the second thermal insulation layer together meet the thermal requirements of NFPA
 1971. 16. The modular personal protective ensemble of claim 1 wherein the full body barrier garment comprises a collar, two sleeves with wristers and cuffs at the end of each of two legs of the trouser portion.
 17. The modular personal protective ensemble of claim 16 wherein at least one of the collar, wristers and cuffs includes a particle barrier comprising a membrane or a filtration layer.
 18. The modular personal protective ensemble of claim 11, wherein the first thermal insulation layer comprises one or more of a woven fabric, a non-woven fabric, a knit fabric, a laminate, and a stretch material.
 19. The modular personal protective ensemble of claim 12, wherein the first thermal insulation layer comprises one or more of a woven fabric, a non-woven fabric, a knit fabric, a laminate, and a stretch material.
 20. The modular personal protective ensemble of claim 1 wherein both the jacket and the full body barrier garment include optically reflective portions. 